Continuous material haulage system and method

ABSTRACT

A material haulage system that transports mining materials, such as but not limited to, coal, ore, etc., from a mine is provided. The material transport system includes a continuous conveyor that transports the mining material, a movable assembly that moves and/or supports the continuous conveyor, and a propulsion assembly attached to the movable assembly that maneuver the continuous conveyor through the mine.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent application Ser. No. 61/896,371 entitled “CONTINUOUS MATERIAL HAULAGE SYSTEM AND METHOD” filed on Oct. 28, 2013. The entirety of the above-noted application is incorporated by reference herein.

ORIGIN

The innovation disclosed herein relates to a conveyor and more specifically, to a continuous material haulage system for mining.

BACKGROUND

Belt conveyors are well known and are an efficient means for moving large quantities of materials such as ore, coal and granular stone over a predetermined distance extending either horizontally, vertically or both. Conventional conveyor systems for mining applications utilizes a series of conveyors mounted on wheels so as to make the system easily movable. Because of the manner in which mines are developed and extended, it may be necessary for a relatively long conveyor system to be moved along a substantially curved or serpentine course. Under such circumstances, it can be difficult and time consuming to move the conveyor system when required. It will also be appreciated that it may be necessary to move the conveyor system and to make adjustments to the system fairly frequently as the mining machine advances in a mine. In addition, conventional belt conveyor systems have limited turning capability due to the rigid nature of the belts or conveyors.

SUMMARY

The following presents a simplified summary in order to provide a basic understanding of some aspects of the innovation. This summary is not an extensive overview of the innovation. It is not intended to identify key/critical elements or to delineate the scope of the innovation. Its sole purpose is to present some concepts of the innovation in a simplified form as a prelude to the more detailed description that is presented later.

In an aspect of the innovation a material haulage system that transports mining material from a mine is disclosed and includes a flexible continuous conveyor that transports the mining material, a movable assembly that moves and/or supports the continuous conveyor, and a propulsion assembly attached to the movable assembly that maneuver the continuous conveyor through the mine.

In another aspect of the innovation a mining system for transporting mining material out of a mine is disclosed and includes a continuous miner, a crawler mounted crusher attached to the continuous miner, a material transport system attached to the crawler mounted crusher that transports the mining material out of the mine and includes a flexible tube made from a composite material, and a plurality of propulsion units attached to the material transport system that maneuver the continuous conveyor through the mine.

In still yet another aspect of the innovation a method of mining material is disclosed and includes providing a flexible continuous conveyor having a material receiving end and a material discharge end, receiving mining material at the receiving end of the material transport system, shaping the flexible conveyor into a continuous tubular shape with rollers such that each end of the conveyor overlaps each other, and conveying the mining material from the material receiving end to the material discharge end, wherein the flexible continuous conveyor is made from a composite material that facilitates turning of the flexible continuous conveyor.

To accomplish the foregoing and related ends, certain illustrative aspects of the innovation are described herein in connection with the following description and the annexed drawings. These aspects are indicative, however, of but a few of the various ways in which the principles of the innovation can be employed and the subject innovation is intended to include all such aspects and their equivalents. Other advantages and novel features of the innovation will become apparent from the following detailed description of the innovation when considered in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram illustration of a mining system in accordance with an aspect of the innovation.

FIG. 2 is a top view of a material transport system in accordance with the innovation

FIG. 3 is a front view of a propulsion unit in accordance with an aspect of the innovation.

FIG. 4 is a rear view of the propulsion unit in accordance with an aspect of the innovation.

FIG. 5 is a cut-a-way side view of the material transport system in accordance with an aspect of the innovation.

FIG. 6 is a schematic drawing of one example embodiment of a mining method incorporating the material transport system in accordance with an aspect of the innovation.

FIG. 7 is a block diagram illustration of the fog generation system in accordance with an aspect of the innovation.

FIG. 8 is a block diagram illustration of the electrical system in accordance with an aspect of the innovation.

DETAILED DESCRIPTION

The innovation is now described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the subject innovation. It may be evident, however, that the innovation can be practiced without these specific details. In other instances, well-known structures and devices are shown in block diagram form in order to facilitate describing the innovation.

While specific characteristics are described herein (e.g., thickness), it is to be understood that the features, functions and benefits of the innovation can employ characteristics that vary from those described herein. These alternatives are to be included within the scope of the innovation and claims appended hereto.

Disclosed herein is an innovative maneuverable-continuous material haulage (transport) system that incorporates a flexible (foldable) belt or an enclosed tube made from a composite material, such as but not limited to carbon fiber, to continuously transport mining material, such as but not limited to ore, coal, etc., from inside the mine to outside or near the entrance of the mine for further processing. The composite material is flexible and is “trained to turn” thereby providing improved turning capabilities over conventional material hauling systems. For example, the material transport system is capable of making turns with a radius of approximately 20′ throughout its length while simultaneously continuously transporting mining material. The improved turning capabilities of the innovative material transport system in turn minimizes the size of the bench required for different mining techniques, such as but not limited to high wall mining.

Referring now to the drawings, FIG. 1 is a block diagram illustration of a mining system 10 incorporating the innovative continuous material haulage system 100 (hereinafter “haulage system 100” in accordance with an aspect of the innovation. As illustrated, the mining system 10 further includes a continuous mining machine 200, a crawler mounted material crusher 300 (hereinafter “crusher 300”), a propulsion assembly including multiple propulsion units 400, a fog generator 500, and an electrical system 600.

Referring to FIGS. 2-5, the material haulage system 100 includes a material receiving end 102 and a material discharge end 104 whereby the material flows from the material receiving end 102 toward the material discharge end 104 as indicated by the arrow A. The material receiving end 102 attaches to the crusher 300 via a belt 105 to thereby transition the mining material from the crusher 300 to the haulage system 100. The haulage system 100 further includes a conveyor 106 that transports the material, a movable/support assembly 108 that facilitates movement and/or support of the conveyor 106, and a propulsion assembly comprised of one or more propulsion units 400, described further below, that propels the material transport system 100 through the mine.

The conveyor 106 may be a flexible belt conveyor that includes a flexible or foldable belt 110 in accordance with one aspect of the innovation. The flexible belt 110 is disposed inside a tubular framed structure described further below. The flexible belt 110 has foldable or pliable features, such that the flexible belt 110 can partially or fully wrap around the material during transport of the material from the receiving end 102 to the discharge end 104. For example, in one embodiment, at various locations from the receiving end 102 to the discharge end 104, the flexible belt 110 may flex or fold so as to form a concave arc, or a U-shape partially around the material.

In another example embodiment shown in FIGS. 3 and 4, during transport of the material, outside ends 112 of the flexible belt 110 may overlap thereby enclosing the material within the flexible belt 110. This configuration contains the material within the flexible belt 110, which in turn decreases the amount of spillage or waste. Mechanical flexors, described further below, are provided that flex or fold the belt in the desired shape (e.g., arc, U-shape, circular, elliptical, etc.) described above.

As mentioned above, the material transport system 100 includes a movable/support assembly 108 that attaches to each propulsion unit 400, which are described further below. The movable/support assembly 108 moves the flexible belt 110 through a conveyor path. The conveyor path is an orbital path that the flexible belt 110 travels during operation of the material transport system 100 and includes a transport path 114 and a return path 116. The transport path 114 is the path that conveys the material from the material receiving end 102 to the material discharge end 104 and the return path 116 is the path that the flexible belt 110 travels upon its return from the discharge end 104 to the receiving end 102. The movable/support assembly 108 includes a tubular framed support 118, multiple mechanical flexors (e.g., rollers, rails, guides, etc.) 120, multiple return rollers 122, and multiple disc rollers 124.

The tubular framed support 118 is a framed structure that attaches to each propulsion unit 400 via one or more fastening devices 126, such as but not limited to, coupling pins, bolts, rivets, etc. (see FIG. 3) and extends from the material receiving end 102 to the material discharge end 104. The tubular framed support 118 is a polygonal, circular, elliptical, etc. shaped frame made from a similar material (e.g., a composite material, such as but not limited to carbon fiber) as the flexible belt 110. As mentioned above, the composite material has enhanced flexible characteristics thereby providing improved turning capabilities over conventional material hauling systems. Although, the tubular framed support 118 shown in the figures has a square cross section, the cross sectional shape can be any shape, such as but not limited to, any polygonal cross section (e.g., hexagonal, square, rectangular, triangular, etc.), circular, elliptical, etc.

Mechanical flexors 120, such as but not limited to, rollers (shown), rails, guides, etc. are disposed inside and attached to the tubular framed structure 118 and are configured to flex or fold and guide the flexible belt 110 through the transport path 114, as described above. Although, rollers are illustrated in the figures, it is to be understood that the example embodiment is for illustration purposes only and is not intended to limit the scope of the innovation.

Multiple sets of mechanical flexors (or rollers in this example) 120 are spaced at predetermined lengths along the transport path 114 and are configured in a circular arrangement. For example, FIG. 4 shows two sets of mechanical flexors 120 spaced at a predetermined distance from each other are included in the propulsion units 400, although this number can vary depending on several factors including, length of the material transport system 100, the type of mining, the material to be mined, etc. In one aspect, one or more mechanical flexors 120 or one or more sets of mechanical flexors 120 may act as a drive device to drive the flexible belt 110 through the conveyor path.

The return rollers 122 and the disc rollers 124 are disposed on a bottom portion of the tubular framed structure 118 and are configured to flatten the flexible belt 110 while the flexible belt 110 is traveling in the return path 116. In one example embodiment, the return roller 122 may attach via a bracket(s) to the bottom portion or to the side portions of the tubular framed structure 118 and the disc rollers 124 may attach to the bracket(s). In one aspect, one or more return rollers 122 and/or one or more disc rollers 124 may act as a drive roller to drive the flexible belt 110 through the conveyor path.

In another aspect, the movable assembly 108 may include independent or additional drive components, such as but not limited to, pneumatics, hydraulics, carbon composite auger or screw, rollers, rails, gears, chains, etc., that drives and guides the flexible belt 110 through the conveyor path.

Still referring to FIGS. 2-5, the propulsion assembly may be comprised of one or more propulsion units 400, such as but not limited to track type crawler units, track type idler units, wheel type driven axle units, wheel type idler axle units, etc. The material transport system 100 may include any number of propulsion units 400 based on the length of the material transport system 100. In lieu of the crusher 300, a first transition propulsion unit may be included to couple the continuous miner 110 to the receiving end 102 of the material transport system 100. In addition, a second transition propulsion unit may be included to couple the discharge end 104 of the material transport system 100 to an apparatus that removes and/or receives the material from the material transport system 100. The propulsion units 400 may be spaced apart from each other at a length (e.g., 5′-60′) that facilitates efficient turning and maneuvering of the material transport system 100. Each propulsion unit 400 can operate independently or as a single entity. Thus, it is to be understood that any number of propulsion units 400 may be included in the material transport system 100 and, thus, the material transport system 100 can vary in length. As such, the illustration in FIG. 2 is for simplicity and is not intended to limit the scope of the innovation.

Each propulsion unit 400 includes a track 402 disposed on each side connected by an axle 404. A protective cover 406 attaches to the axel 404 adjacent to each track 402 and extends over the tubular framed structure 118 to provide protection to the conveyor 106 and the movable/support assembly 108. The protective cover 406 is a continuous cover that extends from the material receiving end 102 to the material discharge end 104 and is made from a similar material as the conveyor 106 and the tubular framed structure 118 to thereby facilitate flexibility and turning capabilities.

Continuous tubular upper and lower connectors 408, 410 are provided that extend from the material receiving end 102 to the material discharge end 104. The upper tube 408 may be attached to a top of the tubular framed structure 118 and the lower connector 410 may be attached to the axel 404. The connectors 408, 410 provide a connection between adjacent propulsion units 400 for additional support and are made from a similar material as the flexible belt 110.

Smaller driven and/or non-driven trailer units may be disposed between adjacent propulsion units 400 to provide additional support to the conveyor 106, the movable/support assembly 108, and the protective cover 406. The trailer units also include tracks connected with an axel and may also the house mechanical flexors 120, the return rollers 122, and the disc rollers 124.

In another example embodiment, as mentioned above, the conveyor 106 may be in the form of an enclosed-sealed-flexible tube (hereinafter “tube”) made from the composite material, such as but not limited to carbon fiber mentioned above. The tube encloses the material and extends from the material receiving end 102 to the material discharge end 104. The tube decreases the amount of material loss during transport of the material from the material receiving end 102 to the material discharge end 104.

In conjunction with the tube embodiment, the material transport system 100 may utilize dense phase conveying to move the material from the material receiving end 102 to the material discharge end 104. Specifically, the material can be moved through the tube conveyor via an air conveyance by blowing air through the tube conveyor from the material receiving end 102 toward the material discharge end 104 and/or a vacuum conveyance where a vacuum is generated at the material discharge 104 to thereby pull the material through the tube conveyor from the material receiving end 102 to the material discharge end 104. It is to be understood, that other techniques may be used to move the material through the tube and that the techniques disclosed herein are not limiting to the scope of the innovation. Thus, in this embodiment, because the material is conveyed through the tube via air conveyance (or other means), the tube remains stationary and does not travel through the conveyor path 114, 116 described above.

Therefore, the tube can simply replace the flexible belt 110 in the transport path 114, and the return roller 122 and the disc rollers 124 can be eliminated since the tube does not travel. As such, the mechanical flexors 120 described above can be utilized as a support system to support the tube along the transport path 114. The support system may be able to move or shift in any direction with respect to the propulsion units 400 to accommodate movement of material through the tube, movement of the material transport system 100 through a mine, etc. In addition, the support system can include a height adjustment feature that adjusts all or portion(s) of the height of the tube with respect to the propulsion units 400 (or the ground surface) to facilitate movement of the material through the tube. The support system can include components, such as but not limited to, rollers, rails, rods, gears, chains, etc.

The fog generator 500, which may be portable, is provided for dust suppression purposes. In one example embodiment, the fog generator includes a volatilizable chemical container 502, a pump 504 connected to the chemical container 502 via tubing, a centrifuge heater 506 connected to the pump 504 via tubing, an outlet 508 connected to the heater 506 via tubing, and a power cord 510 connected to the pump 504. In operation, the pump 504 applies high pressure to the chemical container 502 to drive the volatilizable chemical into and through the centrifuge-heater 506. The centrifuge-heater 506 adds high heat to the chemical to change the chemical into high pressure gas in coordination with high pressure continually being given to the centrifuge-heater 506. The centrifuge-heater 506 centrifuges heavier particles of the chemical against more highly heated areas of a centrifuge member to provide added pressure to the volatilizable chemical passing through the centrifuge member. The volatilizable chemical exits the fog generator via the outlet 508 thereby providing optimum fog output.

Referring to FIG. 7, the electrical system 600 includes a power source 602 that provides power to all the electrical devices 604, such as motors, drives, lights, PLC, etc. In one example embodiment power cables may be used to transfer power from the power source 602 to the electrical devices 604. In another example embodiment, carbon fiber nanotube conductors 606 can be used in lieu of bulky power cables. The carbon fiber nanotube conductors 606 have enhanced electrical, mechanical (flexible), and optical properties. Thus, the carbon fiber nanotubes conductors 606 further facilitate turning and easier maneuverability of the material transport system 100.

The material transport system may further include a programmable logic control (PLC) system in accordance with another aspect of the innovation. The PLC may include at least one human machine interface (HMI) that communicates, evaluates, and controls the complete unit either simultaneously or as individual components. Sensors or other means are provided and communicate with PLC to guide the system and follow a continuous mining machine (continuous miner) or other machine capable of material extraction along with its attached components (e.g., pipe, tube, tubular belt, pipe belt, flexible belt or any other equipment components necessary for communication, control, drive of said components, and said mining machine or continuous miner) along a variable path for an undetermined distance.

The material transport system my further include a global positioning system (GPS) in accordance with another aspect of the innovation. The GPS can be used maneuver and/or track the location of the material transport system through the mine.

The material transport system my further include a material measuring system in accordance with another aspect of the innovation. The material measuring system measures a density of the material and can also determine how much material to mine and how much material to leave in the mine.

The material transport system may include components from other machines assembled in a fashion to convey the material in a unique way. For example, the continuous miner or machine may include a component that fractures the material from a solid state and deposit the material in a receiver that may size the material by crushing, breaking, etc., the material and then move the material to the material transport system.

The material transport system can include a means to transfer and deposit the material to a semi-permanent haulage system that conveys the material the surface, staging area, floating platform, etc. when used in underground applications. In the surface application, the material transport system deposits the material into or onto a system that will deposit the material into or onto processing equipment, a pile or stack, etc. on the existing surface. In addition, a means can be provided that loads conventional transportation devices (including but not limited to trucks, rail transportation, barges, ships, etc.), and may or may not deposit the material for loading into haulage equipment by other means, or deposit to another receiver to utilize the same or similar system to move the material to a more suitable location for processing and transport.

Processing of the material (such as removal of unwanted impurities or contamination in the material) may or may not be done during the movement of the material through or on the material transport system. In addition, the material transport system may be utilized underground, surface, or underwater applications. The material may vary in size from microscopic to very large, which may be greater or smaller than 1 cubic yard in size for solid pieces or lumps.

The method of transporting the material disclosed herein is suited for current mining methods and is also suited for the unique mining methods for materials, as described herein. The mining method is a unique design and uses (but is not limited to) a network of main entries and cross cuts, panel entries and cross cuts and large pillars, which may in size from 25′×25′ or less to 6,000′×20,000′ or more in any shape such as a rectangle, parallelogram, or irregular shape as necessary to facilitate optimum recovery of the material.

Referring to FIG. 6, main entries may be developed along a perimeter or through a vein or seam of material to be mined in any pattern or distance necessary for optimum recovery of the material. Panel entries may be developed at any angle from the main entries. These panel entries may be for single extraction units or multiple extraction units to mine in unison in a particular pillar or panel of material utilizing the material transport system described herein. The panel entries may be connected by means of multiple cross entries or single entries for the purpose of ventilation as necessary at any time now or in the future.

As shown in FIG. 6, in order to minimize the effect of an obstruction, mining may be done at any angle from one or both sides of the developed panel entries into the large pillars developed for mining. This mining advance in the large pillars may go completely through these pillars or may meet mining from a mining unit similar to the described unit from the other side of said pillar at any distance through the pillar. Mining by the units may be stopped at any time during the cutting cycle through the pillar if adverse mining conditions (e.g., roof or bottom rock roll, shear of the vein or seam by existing shift, or mining conditions that may warrant removal of the machine for the prevention of loss of the machine and or the material movement system) are encountered and a cut thru to the previous mining cycle beside the cut made to accommodate ventilation.

The use of the composite material for the tube or flexible belt provides several advantages. For example, the composite material is flexible and, thus, more maneuverable in tight spaces. In addition, the spacing of the propulsion assemblies eliminates a physical connection between adjacent propulsion assemblies, which in turn eliminates contact between adjacent propulsion assemblies thereby providing for a tighter turning radius (approximately 20 feet) over conventional haulage systems. The material transport system disclosed herein can be provided in various lengths (e.g., 100′, 150′, 200′, 250′, 300′, etc.) can be joined together to form longer lengths (e.g., 1200′×1600′), which is longer than conventional material haulage systems.

Some advantages of both the tube conveyor and the flexible belt conveyor include containing the material during transport, decrease in spillage, decrease in dust, an increase in material transport capacity and, thus, an increase in efficiency, etc.

What has been described above includes examples of the innovation. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the subject innovation, but one of ordinary skill in the art may recognize that many further combinations and permutations of the innovation are possible. Accordingly, the innovation is intended to embrace all such alterations, modifications and variations that fall within the spirit and scope of the appended claims. Furthermore, to the extent that the term “includes” is used in either the detailed description or the claims, such term is intended to be inclusive in a manner similar to the term “comprising” as “comprising” is interpreted when employed as a transitional word in a claim. 

What is claimed is:
 1. A material haulage system that transports mining material from a mine comprising: a flexible continuous conveyor that transports the mining material; a movable assembly that moves and/or supports the continuous conveyor; and a propulsion assembly attached to the movable assembly that maneuver the continuous conveyor through the mine.
 2. The material transport system of claim 1, wherein the flexible continuous conveyor is a flexible belt made from a composite material that folds to partially surround or fully surround the material at various locations along a conveyor path during transport.
 3. The material transport system of claim 2, wherein the movable assembly includes a framed support that attaches to the propulsion assembly.
 4. The material transport system of claim 3, wherein the framed support has a polygonal shaped cross-section.
 5. The material transport system of claim 4, wherein the movable assembly includes mechanical flexors disposed inside the framed structure that fold the flexible belt during transport of the material.
 6. The material transport system of claim 5, wherein the propulsion assembly includes a plurality of propulsion units spaced apart from each other at predetermined intervals that facilitate turning of the material transport system.
 7. The material transport system of claim 1, wherein the flexible continuous conveyor is a flexible tube made from a composite material that facilitates turning of the flexible continuous conveyor.
 8. The material transport system of claim 5, wherein material is transported through the continuous tube via an air conveyance.
 9. The material transport system of claim 5, wherein the material is transported through the continuous tube via a vacuum conveyance.
 10. A mining system for transporting mining material out of a mine comprising: a continuous miner; a crawler mounted crusher attached to the continuous miner; a material transport system attached to the crawler mounted crusher that transports the mining material out of the mine and includes a flexible tube made from a composite material; and a plurality of propulsion units attached to the material transport system that maneuver the continuous conveyor through the mine.
 11. The mining system of claim 10, wherein the material transport system includes a framed support that attaches to the plurality of propulsion units, wherein the framed support has a polygonal shaped cross-section.
 12. The mining system of claim 11 further comprising a fog generator that suppresses dust inside the mine during transport of the mining material.
 13. The mining system of claim 12, wherein the material transport system includes mechanical flexors disposed inside the framed structure that fold the flexible tube during transport of the mining material.
 14. The mining system of claim 13, wherein the plurality of propulsion units spaced are apart from each other at predetermined intervals to facilitate turning of the material transport system.
 15. The mining system of claim 10, wherein the mining material is transported through the continuous tube via an air conveyance.
 16. The mining system of claim 10, wherein the mining material is transported through the continuous tube via a vacuum conveyance.
 17. A method of mining material comprising: providing a flexible continuous conveyor having a material receiving end and a material discharge end; receiving mining material at the receiving end of the material transport system; shaping the flexible conveyor into a continuous tubular shape with rollers such that each end of the conveyor overlaps each other; and conveying the mining material from the material receiving end to the material discharge end, wherein the flexible continuous conveyor is made from a composite material that facilitates turning of the flexible continuous conveyor.
 18. The material transport system of claim 17 further comprising providing a plurality of propulsion units attached to the flexible continuous conveyor at predetermined spaced intervals that facilitate turning of the flexible continuous conveyor.
 19. The material transport system of claim 18, wherein material is transported through the continuous tubular shape via an air conveyance.
 20. The material transport system of claim 18, wherein the material is transported through the continuous tubular shape via a vacuum conveyance. 